Structure and method for a transformer with magnetic features

ABSTRACT

The present disclosure provides a semiconductor device. The semiconductor device includes a first inductor formed on a first substrate; a second inductor formed on a second substrate and conductively coupled with the first inductor as a transformer; and a plurality of micro-bump features configured between the first and second substrates. The plurality of micro-bump features include a magnetic material having a relative permeability substantially greater than one and are configured to enhance coupling between the first and second inductors.

PRIORITY DATA

The present application is a continuation application of U.S. patentapplication Ser. No. 14/107,794, filed Dec. 16, 2013, which is acontinuation application of U.S. patent application Ser. No. 13/340,856,filed Dec. 30, 2011, issued as U.S. Pat. No. 8,610,247, each of which isincorporated by reference in its entirety.

CROSS REFERENCE

The following commonly-assigned U.S. patent applications, areincorporated herein by reference: U.S. Ser. No. 13/313,240 filed Dec. 7,2011, by inventors Yu-Ling Lin, Hsiao-Tsung Yen, Ho-Hsiang Chen, andChewn-Pu Jou for “IMPROVED INTEGRATED CIRCUIT GROUND SHIELDINGSTRUCTURE”; and U.S. Ser. No. 13/280,786 filed Oct. 25, 2011 byinventors Hsiao-Tsung Yen, Yu-Ling Lin, Chin-Wei Kuo, Ho-Hsiang Chen,and Min-Chie Jeng for “STRUCTURE AND METHOD FOR HIGH-K TRANSFORMER WITHCAPACITIVE COUPLING”.

BACKGROUND

The semiconductor integrated circuit (IC) industry has experienced rapidgrowth. Technological advances in IC materials and design have producedgenerations of ICs where each generation has smaller and more complexcircuits than the previous generation. However, these advances haveincreased the complexity of processing and manufacturing ICs and, forthese advances to be realized, similar developments in IC processing andmanufacturing are needed. In the course of integrated circuit evolution,functional density (i.e., the number of interconnected devices per chiparea) has generally increased while geometry size (i.e., the smallestcomponent (or line) that can be created using a fabrication process) hasdecreased.

Various active or passive electronic components can be formed on asemiconductor IC. For example, a transformer may be formed as a passiveelectronic component. As device sizes continue to decrease for evenhigher frequency applications, traditional transformer structures mayencounter problems, such as reduced mutual inductive coefficient K andreduced self-resonant frequency. Particularly, the coupling efficiencydrops down with decreased device size by advancing technology nodes.

Therefore, a structure of a transformer and a method making the same areneeded to address the above issues.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the followingdetailed description when read with the accompanying figures. It isemphasized that, in accordance with the standard practice in theindustry, various features are not drawn to scale. In fact, thedimensions of the various features may be arbitrarily increased orreduced for clarity of discussion.

FIG. 1 is a flowchart of method to fabricate a semiconductor devicehaving a transformer with capacitive coupling features in one or moreembodiments.

FIG. 2 is a sectional view of a semiconductor device having atransformer integrated with magnetic features constructed according toaspects of the present disclosure in one or more embodiments.

FIG. 3 a is a perspective view of a magnetic feature of FIG. 2constructed according to aspects of the present disclosure in otherembodiments.

FIGS. 3 b, 3 c, 3 d and 3 e are top views of the magnetic feature ofFIG. 3 a constructed according to various embodiments.

FIG. 4 is a top view of a transformer integrated with a plurality ofmagnetic features constructed according to various aspects of thepresent disclosure in one embodiment.

FIG. 5 is a sectional view of a semiconductor device having atransformer integrated with magnetic features constructed according toaspects of the present disclosure in one or more other embodiments.

FIG. 6 is a top view of a transformer integrated with a plurality ofmagnetic features constructed according to various aspects of thepresent disclosure in another embodiment.

FIG. 7 is a sectional view of a semiconductor device having atransformer integrated with magnetic features constructed according toaspects of the present disclosure in another embodiment.

FIG. 8 is a sectional view of a semiconductor device having atransformer integrated with magnetic features constructed according toaspects of the present disclosure in another embodiment.

FIG. 9 is a perspective view of an inductor constructed according toaspects of the present disclosure in another embodiment.

FIGS. 10 and 11 are perspective views of a transformer integrated with aplurality of magnetic features constructed according to various aspectsof the present disclosure in various embodiments.

DETAILED DESCRIPTION

It is understood that the following disclosure provides many differentembodiments, or examples, for implementing different features of variousembodiments. Specific examples of components and arrangements aredescribed below to simplify the present disclosure. These are, ofcourse, merely examples and are not intended to be limiting. Forexample, the formation of a first feature over or on a second feature inthe description that follows may include embodiments in which the firstand second features are formed in direct contact, and may also includeembodiments in which additional features may be formed between the firstand second features, such that the first and second features may not bein direct contact. In addition, the present disclosure may repeatreference numerals and/or letters in the various examples. Thisrepetition is for the purpose of simplicity and clarity and does not initself dictate a relationship between the various embodiments and/orconfigurations discussed.

Illustrated in FIG. 1 is a flowchart of a method 20 for fabricating asemiconductor device that includes a transformer structure. FIG. 2 is aschematic view of a semiconductor structure 50 having a transformerintegrated with one or more magnetic features constructed according toaspects of the present disclosure in other embodiments. Thesemiconductor structure 50 and the method 20 are collectively describedbelow with reference to FIGS. 1 and 2.

The semiconductor structure 50 may include an integrated circuit (IC)chip, system on chip (SoC), or portion thereof, that may include variouspassive and active microelectronic devices such as resistors,capacitors, inductors, diodes, metal-oxide semiconductor field effecttransistors (MOSFET), complementary metal-oxide semiconductor (CMOS)transistors, bipolar junction transistors (BJT), laterally diffused MOS(LDMOS) transistors, high power MOS transistors, or other types oftransistors. It is understood that the Figures discussed herein havebeen simplified for a better understanding of the inventive concepts ofthe present disclosure. Accordingly, it should be noted that additionalprocesses may be provided before, during, and after the method 20 ofFIG. 1, and that some other processes may only be briefly describedherein.

The method 20 begins with block 22 in which a substrate 52 is provided.The substrate 52 includes a surface 53 that defines an axis “Z”perpendicular to the surface 53. The substrate 52 may include asemiconductor substrate, such as silicon substrate, or other suitablesubstrate. Alternatively or additionally, the substrate 52 includesgermanium, silicon germanium or other proper semiconductor materials.The substrate 52 also includes various isolation features, such asshallow trench isolation (STI), formed in the substrate to separatevarious devices. The semiconductor substrate also includes various dopedregions such as n-well, p-wells, light doped drain (LDD) features andheavily doped source and drain (S/D) features. Those doped features andother features (e.g., gate electrode) are configured to form variousactive and passive devices. Various devices may be formed on thesubstrate 52, such as field effect transistors (FETs). In one example,the FETs includes complementary metal-oxide-semiconductor FETs(CMOSFETs) that have n-type FETs and p-type FETs integrated into afunctional circuit.

The method 20 continues with block 24 in which an interconnect structure54 is formed on the substrate 52. The interconnect structure 54 includesa plurality of conductive lines interconnected by a plurality of vias(or via features). Particularly, the interconnect structure includesmultiple metal layers, such as metal one M₁, metal two M₂ and so on. Themetal layers are perpendicular to the axis Z. The plurality ofconductive lines belong to respective metal layers. The conductive lines(metal lines) and via features are configured to provide horizontal andvertical routings, respectively. The conductive lines and via featuresare couple with the various devices on the substrate, forming one ormore functional circuits. Furthermore, the interconnect structure isdesigned to provide electrical routings between the devices andinput/output signals.

In another embodiment, each of the metal lines and via features furtherincludes a barrier layer and bulk metal where the barrier layer isdisposed to separate the bulk metal from the adjacent dielectricmaterial. In one example, the barrier layer includes titanium nitride,tantalum nitride or other suitable material to prevent inter-diffusionbetween the bulk metal and the dielectric material. In another example,the bulk metal includes copper, aluminum (or aluminum copper alloy),tungsten or other suitable metal. In yet another example, the dielectricmaterial includes silicon oxide, low k dielectric material or otherdielectric material to provide isolation among various metal lines andvia features.

The interconnect structure 54 is formed in a manner such that atransformer 56 is formed in the interconnect structure. The transformer56 is formed with at least some of the conductive lines and at leastsome of the vias of the interconnect structure 54. In one embodiment,the transformer includes a first inductor 62 and a second inductor 64configured to be inductively coupled. Particularly, the first inductor62 includes a first coil element and the second inductor 64 includes asecond coil element. The first inductor 62 further includes first twoports extended from the first coil element and connected to one ofinput/output signals. Similarly, the second inductor 64 includes secondtwo ports connected with another one of input/output signals. One of thefirst inductor 62 and second inductor 64 is configured as a primary coilof the transformer 56 and the another is configured as a secondary coil.

The transformer 56 defines a mutual inductance M between the first andsecond inductors 62 and 64. A coupling coefficient K is defined to thetransformer as well. The coupling coefficient K ranges between 0 and 1.The mutual inductance is related to the coupling coefficient K. In oneexample wherein the transformer 56 only includes the first and secondinductors 62 and 64, the mutual inductance M is related to the couplingcoefficient K defined by M=K(L1*L2)^(1/2), wherein L1 is theself-inductance of the first coil element and L2 is the self-inductanceof the second coil element.

The transformer 56 further includes one or more magnetic feature 66disposed approximate the first and second inductors (62 and 64). Themagnetic feature 66 is configured to enhance the inductive couplingbetween the first and second inductors 62 and 64. The magnetic feature66 includes a magnetic material having a relative permeabilitysubstantially greater than one. In embodiment, the magnetic feature 66includes nickel. In other embodiments, the magnetic feature 66 includesnickel nitride or nickel silicide. In yet another embodiment, themagnetic features 66 includes a magnetic material selected from thegroup consisting of nickel, cobalt, iron, proper alloys thereof andcombinations thereof. The magnetic feature 66 may be formed usingsuitable technologies, such as physical vapor deposition (PVD) orplating. In a particular example, the magnetic feature 66 is neitherelectrically connected with the first inductor 62 nor the secondinductor 64.

The magnetic feature 66 may be designed with a suitable shape. FIG. 3 aillustrates a perspective view of the magnetic feature 66 in oneembodiment. The magnetic feature 66 includes a height H and diameter D.The height H is defined in a direction Z perpendicular to the substratesurface 53 while the diameter D is defined as a horizontal dimension ofthe magnetic feature 66 in a direction parallel with the substratesurface 53. The magnetic feature 66 may include ball, column or othersuitable geometries. In one embodiment, the height H of the magneticfeature 66 is substantially greater than the diameter D thereof. In atop view toward the substrate surface 53, the magnetic feature 66 mayhave a shape as round, rectangle, hexagon, or pentagon such as thoseillustrated in FIGS. 3 b through 3 e according to various embodiments.

In one embodiment, the magnetic feature 66 is configured between thefirst and second inductors 62 and 64 but is not electrically connectedto the first and second inductors 62 and 64. In one example, theplurality of magnetic features 66 are configured in a circle alignedwith the first and second coil elements. In another example, theplurality of magnetic features 66 are configured in a segment of thecircle aligned with the first and second coil elements. In yet anotherexample, the plurality of magnetic features 66 are configured in aregion aligned with a central region surrounded by the first and secondcoil elements. FIG. 4 illustrate one embodiment of the transformer 56 ina top view. The first inductor 62 and the second inductors 64 aredisposed in a same region of the substrate 52. The corresponding coilelements are configured in a ring region that surrounds a centralregion. The plurality of magnetic features 66 are configured in the ringregion to enhance the inductive coupling between the first and secondinductors. The coil elements consist metal lines. In one embodiment,when the metal lines have a width W as illustrated in FIG. 4, thediameter D of the magnetic features is greater than the width of themetal lines. In one example, a ratio D/W ranges between about 5 andabout 20.

As noted above, the interconnect structure 54 includes a plurality ofmetal layers patterned as metal lines to provide horizontal connection.Via features are configured to provide vertical connection betweenneighbor metal layers. Various via features between two neighbor metallayers are referred to as via features in a via layer. In oneembodiment, the first inductor 62 is formed in one or more metal layers.The second inductor 64 is underlying the first inductor and is formed inone or two other metal layer. The magnetic features 66 are formed in avia layer, a metal layer or more metal layers including the via layersconnecting the metal layers.

In another embodiment, the first and second inductors 62 and 64 areintegrated in one or more metal layers and are approximate from eachother such that the mutual inductance is enhanced. In one example, thefirst and second inductors 62 and 64 are disposed in two approximatemetal layers. Each may include metal lines in the two metal layers andvia features between the two metal layers. In furtherance of theembodiment, the first coil element is configured in one metal layer andthe second coil element is configured in another metal layer. The firstand second ports are distributed on the two metal layers and areconnected to the corresponding coil element by via features.Particularly, the magnetic features 66 are formed in the via layerbetween the two approximate metal layers. However, the magnetic features66 include a magnetic material and are not electrically connected withthe first and second inductors. Particularly, the magnetic features 66are distributed in a configuration for enhanced coupling between thefirst and second inductors.

In one embodiment to form the magnetic features 66, a similar method toform via features are used, such as by a damascene method. To preventthe direct contact with the first and second inductors, the via featuresare configured to be offset from the metal lines of the first and secondinductors. In another embodiment, a modified damascene process isutilized to form the magnetic features 66 such that the top surface ofthe magnetic features is below the overlying metal lines and the bottomsurface of the magnetic features is above the underlying metal lines.For example, via holes are formed in an interlayer dielectric layer toexpose the underlying metal lines. A first dielectric layer is thendeposited on the interlayer dielectric layer and the via holes to coverthe exposed metal lines. The magnetic material is disposed on the viaholes and a chemical mechanical polishing (CMP) process may be followedto remove the excessive magnetic material on the interlayer dielectricmaterial. Then a second dielectric material layer is disposed on theinterlayer dielectric material and covers the magnetic features formedin the via holes. In another embodiment where the magnetic features andvia features (for vertical connection) are formed in the same via layer,the magnetic features and the via features are separately formed by aprocedure including lithography patterning. For example, the firstdielectric material layer is only deposited in the via holes formagnetic features while the via holes for via features are covered by apatterned photoresist layer. In another example, the first dielectricmaterial layer is disposed and is then patterned to remove the portionon the via holes for the via features. Similarly, the second dielectricmaterial is disposed only in the region of the magnetic features.

Although not specifically shown for the sake of simplicity, theinterconnect structure 54 further includes one or more dielectricmaterial layers such that the various metal features (metal lines andvia features) are embedded in. The dielectric material layers provideisolation function to the interconnect structure. The dielectricmaterial layers may include silicon oxide, silicon nitride, siliconoxy-nitride, un-doped silicate (USG), fluoride-doped silicate (FSG),and/or a low-k dielectric material. The various interconnection featuresmay implement various conductive materials including copper, tungsten,aluminum or silicide. In one example, a damascene process is used toform copper related interconnect structure. In another example, a metaletch process may be used to form aluminum related interconnectstructure.

Various embodiments of the transformer are illustrated below withreference to respective figures and further described. FIG. 5 is asectional view of a semiconductor device 70 having a transformerconstructed according to various aspects in one or more embodiments.FIG. 6 is a fragmental top view of the semiconductor device 70. Thesemiconductor device 70 includes a transformer 56 integrated in theinterconnect structure 54. In the depicted embodiment, the interconnectstructure 54 includes a plurality of metal layers.

The transformer 56 includes a first conductive feature 62 and a secondconductive feature 64 configured to be inductively coupled. The firstinductor 62 includes a first coil element. Each of the first and secondinductors further includes first two ports extended from the first coilelement and connected with one of input/output signals. Particularly,the coil elements of the first inductor 62 and the second inductor 64are formed in a ring region surrounding a central region. The magneticfeatures 66 are disposed in the central region and are surrounded by thefirst and second inductors as illustrated in FIG. 6. In one example, themagnetic features 66 are vertically extended from the first inductor 62to the second inductor 64. The magnetic features 66 may be shaped andsized similar to the magnetic features 66 of the transformer 56 of FIG.2.

FIG. 7 is a sectional view of an integrated circuit structure 80 havinga transformer constructed according to aspects of the present disclosurein another embodiment. The integrated circuit device 80 includes a firstsubstrate 82 and a second substrate 84 stacked and bonded together. Inone embodiment, the first substrate 82 is an integrated circuit chip andthe second substrate 84 is an interposer configured between the firstsubstrate and a third substrate (such as another integrated circuitchip) for chip-stacking in three dimensional integrated circuitstructure. Particularly, the first substrate 82 is attached to a firstside of the interposer 84 and a third substrate (not shown) is attachedto a second side of the interposer 84.

An transformer 56 is formed in the integrated circuit structure 80. Thetransformer 56 includes a first inductor 62 formed on the firstsubstrate 82. In the present embodiment, an interconnect structure isformed on the first substrate 82 and the first inductor 62 is integratedin the interconnect structure of the first substrate 82. For example,the first inductor 62 is distributed in one or more metal layers in theinterconnect structure. The first inductor 62 is similar to the firstinductor 62 of FIG. 2 in term of structure according to one embodiment.In other examples, the first substrate 82 may include silicon or othersemiconductor material. Various devices, such as field effecttransistors, are formed on the first substrate 82 and are coupledthrough the interconnect structure.

The transformer 56 includes a second inductor 64 formed on the secondsubstrate 84 as an interposer in the present embodiment. The secondinductor 64 is formed in the interposer 84. The second inductor 64 issubstantially aligned with the first inductor 62, in a top view, for aproper inductive coupling between the first and second inductors. In thepresent embodiment, the interposer includes conductive features and thesecond inductor 64 is integrated in the conductive features of theinterposer. In one example, the interposer 84 includes a substrate and aplurality of through-substrate-vias (TSVs) formed in the substrate toprovide electrical interconnection. In one embodiment, the substrate ofthe interposer 84 is a silicon substrate. In this case, the throughsubstrate vias may also be referred to as through silicon vias. Thesecond inductor 64 is integrated in the TSVs. In another example, theinterposer 84 includes metal traces formed in a surface layer of theinterposer for bonding and electrical interconnection. The secondinductor 64 is integrated with the metal traces. The second substrate 84may include silicon or other material.

The transformer 56 also includes one or more magnetic features 86disposed between the first inductor 62 and the second inductor 64. Themagnetic features 86 are configured to be aligned with the firstinductor 62 and second inductor 64 in a same region such that theinductive coupling between the first and second inductors is enhanced.Particularly, the magnetic features 86 are sandwiched between the firstinductor 62 and the second inductor 64. In the present embodiment, themagnetic features 86 are neither electrically connected with the firstinductor 62 nor the second inductor 64. In one example, the magneticfeatures 86 are configured in a ring region aligned with thecorresponding coil elements of the first and second inductors. Themagnetic features 86 are similar to the magnetic features 66 in term ofcomposition according to one embodiment. The magnetic features 86include a magnetic material having a relative permeability substantiallygreater than one. For example, the magnetic features 86 include nickel,cobalt or iron. In another example, the magnetic features 86 includenickel nitride or nickel silicide.

The magnetic features 86 may be shaped to ball, column or other suitablegeometries. In one embodiment, the height of the magnetic features 86 issubstantially greater than the diameter thereof. In a top view, themagnetic features 86 may have a shape as round, rectangle, hexagon, orpentagon such as those illustrated in FIGS. 3 b through 3 e according tovarious embodiments. In another embodiment, when the inductors includemetal lines of a width W, the diameter D of the magnetic features isgreater than the width of the metal lines. In one example, a ratio D/Wranges between about 5 and about 20.

The first substrate 82 and the interposer 84 are bonded together througha plurality of conductive bumps 88. The conductive bumps 88 provide abonding mechanism between the first substrate 82 and the substrate 84(the interposer in the present embodiment). The conductive bumps 88 alsoprovide electric routing between the first and second substratesthrough. In the present embodiment, the magnetic features 86 areintegrated with the conductive bumps 88, collectively referred to asmicro-bumps. Therefore the magnetic features 86 are at least a subset ofthe micro-bumps. However, the magnetic features 86 have a relativepermeability substantially greater than one. In one embodiment, themagnetic features 86 include a first material and the conductive bumpsinclude a second material different from the first material. The firstmaterial is chosen for higher permeability and the second material ischosen for bonding effect and electrical interconnection. In anotherembodiment, the magnetic features 86 and the conductive bumps include asame material tuned for higher permeability, bonding effect and electricinterconnection.

In one embodiment, various bonding features are respectively formed onthe first and second substrates (82 and 84). Then the first and secondsubstrates are aligned and positioned together such that thecorresponding bonding surfaces face each other and the respectivebonding features are physically contacted and merged together to themicro-bumps through proper bonding mechanism, such as thermal effect andmechanical effect. The conductive bumps 88 provide electrical routingand mechanical bonding through metal traces formed on the first andsecond substrates according to one embodiment. Then an under-fillmaterial 89 is disposed into the space between the first substrate 82and the second substrate 84 for proper packaging effect, such asbonding, sealing and/or insulation. The under-fill material 89 includesa suitable dielectric material, such as a polymeric material for thepackaging effect. In the present embodiment, the micro-bumps includingthe magnetic features 86 are embedded in the under-fill material. In oneexample, the under-fill material 89 has a thickness greater than about10 micron. In another example, the under-fill material 89 has athickness ranging between about 20 micron and about 50 micron.

In another embodiment, FIG. 8 is a sectional view of an integratedcircuit structure 90 having a transformer constructed according toaspects of the present disclosure in another embodiment. The integratedcircuit device 90 includes a first substrate 92 and a second substrate94 attached into an interposer 96. Particularly, the first substrate 92is attached to a first side of the interposer 96 and the secondsubstrate 94 is attached to a second side of the interposer 96 throughconductive bumps formed on the corresponding bonding surfaces. In thepresent embodiment, the first substrate 92 is a first integrated circuitdie and the second substrate 94 is a second integrated circuit die. Theinterposer 96 includes a plurality of conductive features embedded in asubstrate, such as a dielectric substrate or a silicon substrate.

An transformer 56 is formed in the integrated circuit structure 90. Thetransformer 56 includes a first inductor 62 formed on the firstsubstrate 92. In the present embodiment, a first interconnect structureis formed on the first substrate 92 and the first inductor 62 isintegrated in the first interconnect structure. For example, the firstinductor 62 is distributed in one or more metal layers of the firstinterconnect structure. The first inductor 62 is similar to the firstinductor 62 of FIG. 2 in term of structure according to one embodiment.The first substrate 92 may include silicon or other semiconductormaterial. Various devices, such as field effect transistors, may beformed on the first substrate 82.

The transformer 56 includes a second inductor 64 formed on the secondsubstrate 94. The second inductor 64 is substantially aligned with thefirst inductor 62, in a top view, to achieve a proper inductive couplingbetween the first and second inductors. In the present embodiment, asecond interconnect structure is formed on the second substrate 94 andthe second inductor 64 is integrated in the second interconnectstructure. For example, the second inductor 64 is distributed in one ormore metal layers of the second interconnect structure. The secondinductor 64 is similar to the second inductor 64 of FIG. 2 in term ofstructure according to one embodiment. The second substrate 94 mayinclude silicon or other semiconductor material. Various devices, suchas field effect transistors, may be formed on the second substrate 94.

The transformer 56 also includes one or more magnetic features 98embedded in the interposer 96. The magnetic features 98 are configuredto be aligned with the first inductor 62 and second inductor 64 in asame region such that the inductive coupling between the first andsecond inductors is enhanced. Particularly, the magnetic features 98 aresandwiched between the first inductor 62 and the second inductor 64. Inthe present embodiment, the magnetic features 98 are neitherelectrically connected with the first inductor 62 nor the secondinductor 64.

The magnetic features 98 may be shaped to ball, column or other suitablegeometries. In one embodiment, the height of the magnetic features 98 issubstantially greater than the diameter thereof. In a top view, themagnetic features 98 may have a shape as round, rectangle, hexagon, orpentagon such as those illustrated in FIGS. 3 b through 3 e according tovarious embodiments. In another embodiment, when the inductors includemetal lines of a width W, the diameter D of the magnetic features isgreater than the width of the metal lines. In one example, a ratio D/Wranges between about 5 and about 20.

In one example, the magnetic features 98 are configured in a ring regionaligned with the corresponding coil elements of the first and secondinductors. The magnetic features 98 are similar to the magnetic features66 in term of composition according to one embodiment. The magneticfeatures 98 include a magnetic material having a relative permeabilitysubstantially greater than one. For example, the magnetic features 98include nickel, cobalt or iron. In another example, the magneticfeatures 98 include nickel nitride or nickel silicide.

The interposer 96 includes a plurality of conductive bumps embedded in asubstrate of a dielectric material or other suitable material, such as asilicon substrate. The interposer 96 provides an interface to bond thefirst and second substrates and provides an electric routing between thefirst and second substrates through the conductive features, such asthrough substrate vias (TSVs). The TSVs include one or more conductivematerial formed by substrate etch and deposition. In the presentembodiment, the magnetic features 98 are integrated with the TSVs.However, the magnetic features 98 have a relative permeabilitysubstantially greater than one. In one embodiment, the magnetic features98 include a magnetic material for inductive coupling enhancement andthe magnetic material is different from the conductive material (such asmetal) of TSVs in composition. The magnetic material is chosen forhigher permeability and the conductive material is chosen for bondingeffect and electrical interconnection. In another embodiment, themagnetic features 98 and the TSVs include a same material tuned forhigher permeability, bonding effect and electric interconnection.

Various embodiments of the transformer are provided according to theaspects of the present disclosure, such as the transformer 56 in theintegrated circuit structure 80 or 90. Various advantages may present indifferent embodiments. In addition to utilizing magnetic features in thetransformer, the spacing between the magnetic features and firstinductor 62 (or the second inductor 64) has a large tunable range tooptimize different parameters of the transformer, including inductivecoupling, quality factor, and/or frequency in one or more embodiments.

FIG. 9 is a perspective view of inductor 100 constructed according toaspects of the present disclosure. The inductor 100 include a coilelement having one or more turns (e.g., two turns in the presentexample). Various turns of the coil element are connected through viafeatures in the metal layer in one embodiment. In one embodiment, thefirst coil element includes a first spiral structure disposed in a firstplurality of metal layers and the second coil element includes a secondspiral structure disposed in a second plurality of metal layers over thefirst plurality of metal layers. The magnetic features are formed in thefirst and second plurality of metal layers and are extended through thefirst and second spiral structures. The inductor 100 may be integratedin the transformer 56 of FIG. 2, 70 of FIG. 5, 80 of FIG. 7, or 90 ofFIG. 8 as the first inductor 62 and/or the second inductor 64.

FIG. 10 is a perspective view of transformer 106 constructed accordingto aspects of the present disclosure. The transformer 106 include afirst inductor 62 having a first coil element connected to first ports62 a. The transformer 106 include a second inductor 64 having a secondcoil element connected to second ports 64 a. The first and secondinductors are positioned in a same region and aligned for inductivecoupling. Various magnetic features 66 are sandwiched between the firstand second inductors. The magnetic features 66 are configured in a ringregion aligned with the coil elements of the first and second inductors.The transformer 106 is one embodiment of the transformer 56 in FIG. 2,70 of FIG. 5, 80 of FIG. 7, or 90 of FIG. 8.

FIG. 11 is a perspective view of transformer 108 constructed accordingto aspects of the present disclosure. The transformer 108 include afirst inductor 62 having a first coil element connected to first ports62 a. The transformer 106 include a second inductor 64 having a secondcoil element connected to second ports 64 a. The first and secondinductors are positioned in a same region and aligned for inductivecoupling. Various magnetic features 66 are sandwiched between the firstand second inductors. The magnetic features 66 are configured in asegment of the ring region aligned with the coil elements of the firstand second inductors. The transformer 108 is one embodiment of thetransformer 56 in FIG. 2, 70 of FIG. 5, 80 of FIG. 7, or 90 of FIG. 8.

Although embodiments of the present disclosure have been described indetail, those skilled in the art should understand that they may makevarious changes, substitutions and alterations herein without departingfrom the spirit and scope of the present disclosure. For example, thetransformer is integrated with a 3D stacking structure having a firstdie, a second die and a third die sandwiched between the first andsecond dice. The transformer includes a first inductor integrated in thefirst die and a second inductor integrated in the second die. Thetransformer further includes one or more magnetic features integrated inthe third die.

The present disclosure is not limited to any particular application. Forexample, the disclosed structure of a transformer and method making thesame may be used in any radio frequency integrated circuit (RFIC)applications, such as voltage controlled oscillator (VCO), low noiseamplifier (LNA), impedance matching network or mixer. In anotherexample, the integrated circuit structure (or semiconductor structure)integrated with a transformer having the magnetic features mayadditionally include other structure, such as a dynamic random accesssecond (DRAM) cell, field programmable gate-array (FPGA) and/or othermicroelectronic devices (collectively referred to herein asmicroelectronic devices). Of course, aspects of the present disclosuremay be employed in many different applications, including sensor cells,logic cells, electrostatic discharge ESD circuit application,interconnection with antenna and others.

In various embodiments of a transformer integrated in an integratedcircuit structure (or a semiconductor structure), the transformerincludes two inductors inductively coupled and further includes one ormore magnetic features integrated with the first and second inductors toprovide enhanced coupling to the transformer. Various advantages may bepresent in different examples or embodiments. In one example, spacingbetween the first inductor (or the second inductor) and the magneticfeatures is tunable a large range since the distance between the dice islarger and each inductor can be formed in a lower portion or an upperportion of the corresponding substrate according specific applicationand design need.

A semiconductor device is disclosed according to one of the broaderforms of the present disclosure. In one embodiment, the semiconductordevice includes a first inductor formed on a first substrate; a secondinductor formed on a second substrate and conductively coupled with thefirst inductor as a transformer; and a plurality of micro-bump featuresconfigured between the first and second substrates. The plurality ofmicro-bump features include a magnetic material having a relativepermeability substantially greater than one and are configured toenhance coupling between the first and second inductors.

In one embodiment of the disclosed semiconductor device, the firstsubstrate includes a semiconductor substrate having an integratedcircuit formed thereon; and the second substrate includes is aninterposer bonded to the first substrate. In another embodiment, theinterposer includes a silicon substrate having through-silicon vias.

In yet another embodiment, the micro-bump features are electricallydisconnected from the first inductor and the second inductor.

In yet another embodiment, the semiconductor device further includes adielectric under-fill material disposed between the first and secondsubstrates such that the plurality of micro-bump features are embeddedin the under-fill material. In yet another embodiment, the magneticmaterial includes one of nickel, cobalt and iron. In yet anotherembodiment, the magnetic material is selected from the group consistingof nickel, nickel nitride, and nickel silicide. In yet anotherembodiment, the micro-bump features are shaped to have a diameter and aheight greater than the diameter.

The present disclosure also provides another embodiment of asemiconductor device. The semiconductor structure includes asemiconductor substrate having an integrated circuit (IC) device; aninterconnect structure disposed on the semiconductor substrate andcoupled with the IC device; and a transformer disposed on thesemiconductor substrate and integrated in the interconnect structure.The transformer includes a first inductor, a second inductorconductively coupled with the first inductor, and a magnetic featurethat is disposed approximate the first and second inductors and isconfigured to enhance inductive coupling between the first and secondinductors.

In one embodiment of the disclosed semiconductor device, the magneticfeature includes a magnetic material having a relative permeabilitysubstantially greater than one. In another embodiment, the magneticfeature includes a magnetic material selected from the group consistingof nickel, iron, cobalt, or combinations thereof. In yet anotherembodiment, the magnetic feature is configured between the first andsecond inductors and is not electrically connected to the first andsecond inductors.

In yet another embodiment, the interconnect structure includes aplurality of metal layers having a first metal layer, a second metallayer and a via layer disposed therebetween; the first inductor isdisposed in the first metal layer; the second inductor is disposed inthe second metal layer; and the magnetic feature is disposed in the vialayer.

In yet another embodiment, the magnetic feature includes a plurality ofsub-features separated and distributed between the first and secondinductors.

In yet another embodiment, the semiconductor substrate has a topsurface; each of the sub-features of the magnetic feature has adimension D in a top view toward to top surface; and each of the firstand second inductors includes a metal line with a width W, wherein aratio D/W ranges between about 5 and about 20.

In yet another embodiment, the first inductor includes a first spiralstructure disposed in a first plurality of metal layers; the secondinductor includes a second spiral structure disposed in a secondplurality of metal layers over the first plurality of metal layers; andthe magnetic feature is formed in the first and second plurality ofmetal layers and is extended through the first and second spiralstructures. In yet another embodiment, each of the first and secondinductors includes multiple turns.

The present disclosure also provides another embodiment of an integratedcircuit (IC) structure. The IC structure includes a first substratehaving a first inductor; a second substrate having a second inductorconfigured to couple with the first inductor as a transformer; a throughsubstrate via (TSV) interposer bonded between the first and secondsubstrates and having a plurality of via features embedded therein; andat least a subset of the via features being configured approximate thefirst and second inductors and including a magnetic material with arelative permeability substantially greater than one.

In one embodiment, the subset of via features are configured to beelectrically disconnected from the first and second inductors. Inanother embodiment, the magnetic material is selected from the groupconsisting of nickel, cobalt, iron and combinations thereof.

The foregoing has outlined features of several embodiments so that thoseskilled in the art may better understand the detailed description thatfollows. Those skilled in the art should appreciate that they mayreadily use the present disclosure as a basis for designing or modifyingother processes and structures for carrying out the same purposes and/orachieving the same advantages of the embodiments introduced herein.Those skilled in the art should also realize that such equivalentconstructions do not depart from the spirit and scope of the presentdisclosure, and that they may make various changes, substitutions andalterations herein without departing from the spirit and scope of thepresent disclosure.

1. A device comprising: a first inductor; a second inductor disposedover the first inductor and conductively coupled with the first inductoras a transformer; and a first magnetic feature and a second magneticfeature disposed between the first and second inductors, wherein thefirst and second magnetic features do not physically contact either thefirst inductor or the second inductor.
 2. The device of claim 1, whereinthe first inductor overlaps at least one of the first and secondmagnetic features.
 3. The device of claim 1, wherein the second inductoroverlaps at least one of the first and second magnetic features.
 4. Thedevice of claim 1, wherein the first inductor surrounds the first andsecond magnetic features without overlapping the first and secondmagnetic features.
 5. The device of claim 1, further comprising: a firstsubstrate, wherein the first inductor is disposed on the firstsubstrate; a second substrate, wherein the second inductor is disposedon the second substrate; and a conductive feature disposed between thefirst and second substrates to electrically couple the first and secondsubstrates.
 6. The device of claim 5, further comprising a dielectricmaterial disposed between the first and second substrates, and whereinthe first and second magnetic features extend through the dielectricmaterial, and wherein the conducive feature extends through thedielectric material.
 7. The device of claim 5, wherein the conductivefeature is formed of a first material having a first permeability andthe first magnetic feature is formed of a second material having asecond permeability that is different than the first permeability.
 8. Adevice comprising: a first inductor; a second inductor configured tocouple with the first inductor as a transformer; and a first via and asecond via extending between the first and second inductors, the firstand second vias configured to enhance coupling between the first andsecond inductors, wherein the first and second vias do not physicallycontact either the first inductor or the second inductor.
 9. The deviceof claim 8, wherein at least one of the first and second vias includes amagnetic feature.
 10. The device of claim 8, wherein the first inductorincludes a first ring shape structure and the second inductor includes asecond ring shape structure.
 11. The device of claim 10, wherein thefirst and second ring shape structures do not overlap the first andsecond vias.
 12. The device of claim 10, wherein the first and secondring shape structures overlap the first and second vias.
 13. The deviceof claim 8, further comprising a dielectric material layer separatingthe first and second vias from physically contacting either the firstinductor or the second inductor.
 14. The device of claim 8, wherein thefirst inductor is disposed over a first semiconductor substrate and thesecond inductor is disposed over a second semiconductor substrate.
 15. Adevice comprising: a first inductor; a second inductor disposed over thefirst inductor and conductively coupled with the first inductor as atransformer; and a first magnetic feature and a second magnetic featuredisposed between the first and second inductors, wherein the first andsecond magnetic features are electrically isolated from the firstinductor.
 16. The device of claim 15, wherein the first and secondmagnetic features are electrically isolated from the second inductor.17. The device of claim 15, wherein the first inductor includes a ringstructure having multiple turn sections and wherein the first magneticfeature is overlapped by at least two of the turn sections of the ringstructure.
 18. The device of claim 15, wherein the transformer isdisposed within an interconnect structure.
 19. The device of claim 15,wherein the first magnetic feature has a non-circular cross-sectionalprofile shape.
 20. The device of claim 15, further comprising aplurality of vias extending between the first and second inductors, andwherein the first and second magnetic features are integrated with theplurality of vias, and wherein the first magnetic feature is formed of adifferent material than the plurality of vias.